Air

Compressor
Purchasing Guide

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Introduction to the Air Compressor Buying Process
Whats inside:
Trends
Types
Specs
Choosing a Seller

Introduction

Air tools have become a staple on many jobsites due to the simplicity and advantages they
provide. In fact, its estimated that nearly every industry now relies on compressed air tooling
to some degree. Among their greatest benefits are that they offer the freedom from electricity
and dont require their own motor especially useful in rural areas or temporary locations like
fairgrounds or music festivals. But for these tools to perform in locations that range from urban
to rural, they do require the support of an adequate air compressor.

Air compressors power everything from large industrial production machinery to individual
ratchet and impact wrenches, paint sprayers, and finish nailers. This broad application is where
you often find a couple more major advantages of an air system: versatility and power.
Regardless of the scope or location of your project, an air compressor accommodates the full
range of compatible tools switched as quickly and easily as changing a drill bit. Plus, when
compared to standard tooling, air powered models often provide greater torque and higher
RPMs.

Three types
Air compressors are available in three basic types:

1. Reciprocating Positive displacement compressors that provide increased air pressure

by limiting the volume of air. Available in single-stage and two-stage, theyre typically
capable of outputs ranging from 1 to 15 hp.
2. Rotary screw Positive displacement compressors that are considered simple to
operate and maintain. Favored for their ability to provide continuous duty, their design
provides cooling within the compressors interior, saving the individual parts from
extreme operating temperatures and enabling them to deliver outputs that range from
7.5 to 100 hp and up.

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 3. Centrifugal Compressors that do not rely on positive displacement and are most
effective when running at their full capacity, making them ideal for operating
environments in which demand is continuous and output needs start around 100 hp.

In general, air compressors are highly durable tools. For example, its estimated that a rotary
compressor will last for 40,000 to 60,000 hours the equivalent of full-time operation for 20 to
30 years. With regular maintenance, reciprocating compressors have a life expectancy of 10 to
15 years. Each of the three types also has a number of advantages and disadvantages well
cover in more detail below.

Importance of a professional dealer

Youll quickly discover that air compressor dealers often specialize in a particular brand. The
reason is manufacturers typically require exclusivity among their networks. While this entails a
little more comparison shopping on your part, it ends up being a plus in the long-run.
Specialization enables the dealers to become highly familiar with each of the models theyre
selling, the specific applications theyve been designed for, and the type of service required to
keep them up and running.

This expertise allows them to consult on the exact type of machinery best suited to your
intended application(s) and also offer value-based service packages at a fixed cost that can
help you maintain the investment well into the future. In fact, by some estimates, maintenance
and repair can account for as much as 20% of the total investment on a light-duty or industrial
air compressor.

Estimated costs
The more power you need, the more you can expect to pay. But given the versatility of an air
compressor, a single investment may end up saving you on the purchase of additional tooling
and equipment.

Here are some estimated costs on popular specs:

Portable /
Estimated
Type Horsepower CFM PSI Stationary
Cost
Mounted
Reciprocating 3 - 5 hp 10.3 - 15.5 cfm 135 psi Portable $800 - $1,400
$1,900 -
Reciprocating 7.5 hp 24 cfm 175 psi Portable
$2,200
$2,700 -
Rotary Screw 10 hp 34 cfm 175 psi Portable
$5,200
$2,900 -
Rotary Screw 15 hp 46 cfm 175 psi Portable
$7,500
$12,000 -
Rotary Screw 80 hp 185 cfm 80 - 125 psi Stationary
$17,500

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 $17,000 -
Centrifugal 20 - 200hp 14.3 - 998 cfm 75 - 150 psi Stationary
$24,000
1466 - 2444 109 - 125 $35,000 -
Centrifugal 250 - 500hp Stationary
cfm psi $90,000

Trends

Your specific application and the horsepower required to achieve it effectively will largely
determine the air compressor you purchase. But there are a number of trends that may also
factor into your purchase decision. The incorporation of one or more of the following has the
potential to significantly increase the productivity and cost-effectiveness of your process.

Which of the following could apply to you?

Variable speed drive

This development uses variable speed technology and a special drive to control the speed of
the unit, saving substantial energy up to 35% less with some models when compared to a
fixed speed air compressor. With this vast potential for savings, some dealers cite variable
speed drives as superior to all other control technologies on the market today.

In short, a variable speed drive automatically pairs its output to the users demand for air. The
continuous, real-time nature of this development is what provides its peerless energy
efficiency, reducing demands for power and fuel while also cutting emissions. Further cost and
energy savings are found in its ability to provide unlimited motor starts, progressing from zero
to full load without spikes in electric current or generating surplus heat.

Tier 4 engines
The Tier 4 category is known for its adherence to EPA guidelines regarding emissions control.
But Tier 4 engines often manufactured by leading brands like Caterpillar and John Deere
also provide fuel efficiencies that can save you on the total cost of ownership for a diesel-based
air compressor.

Many of the top air compressors that incorporate Tier 4 engines are easily capable of 300 to
425 cfm at 100 to 200 psig. They feature advanced electronic control systems that include
easy-to-read gauges and an LCD display, allowing the user to quickly adjust specific factors to
achieve the optimum combination of performance and cost-effectiveness.

Though not standard to all, some models further extend their value through design
enhancements. These can include a frame engineered for full fluid containment as well as easy
access service doors that simplify service and maintenance for the fuel tank, engine, air filters,
and other vital compartments.

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Greater capacity, lower power requirements
The goal of almost every technology is to produce more with less. Air compressor
manufacturers have pursued this goal by delivering ever higher levels of output on less fuel.
One way they do it is through lower operating temperatures. By redesigning their compressors
with lower internal temperatures, new models provide noticeable improvements in volumetric
and electrical efficiencies.

Another aspect is seen in a trend we covered above: variable speed drive. Consider for example
a rotary screw air compressor. Often integrated into woodworking and spray painting
operations, auto body service and repair shops, and even larger industrial operations, they are
often not a continuous use machine that has to operate at full capacity. In these situations, a
variable speed drive is able to compensate for shifting power demands and monetize them
saving fuel, not to mention unnecessary wear and tear on machine parts. As mentioned above,
this technology can reduce energy costs by more than a third, with some variable speed
compressors even capable of operating on 40% less energy than their standard counterparts.

Oil-free rotary screw compressors

Essentially maintenance-free, oil-free or oil-less air compressors are permanently lubricated
through a long-lasting treatment of Teflon or a similar synthetic resin. While oil free models
arent ideal for continuous use applications, theyre great for short duty and home use. Theyre
also becoming one of the preferred types for spray painting outfits and other operations that
require clean work environments. The reason is that oil-lubricated compressors discharge a
small amount of oil in the form of mist, a design limitation that makes the mess difficult for
some applications.

In addition to maintenance costs that are practically non-existent, oil-free compressors also
tend to be less expensive due to a design that requires fewer parts. This minimalist design also
makes them lighter, great for those needing portability.

Types

As mentioned briefly in the introduction, air compressors are divided into three main types:

1. Reciprocating compressors
2. Rotary screw compressors
3. Centrifugal compressors

Within these three types, there are two different varieties. The more common of the two,
encompassing two of the three types, operates through the use of positive displacement.

Positive displacement is a mechanical design that generates air pressure through a pump thats
split into two sides, suction and discharge. These two sides or cavities expand and decrease as
air is pulled into the suction compartment and released on the discharge side during the

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compression stroke. Positive displacement is common among reciprocating and rotary screw
air compressors because of its suitability to compressing small amounts of air into high
pressures, as well as its ability to quickly disperse the heat resulting from compression.

With that in mind, the air compressor you select will be determined by a number of specific
factors including power output requirements and portability.

Heres how the three types compare.

Reciprocating air compressors

Reciprocating compressors are positive displacement models. The same volume of air that
enters the compression chamber leaves the cylinder, pressurized to the necessary PSI. Usually
falling on the smaller end of the output scale, reciprocating models feature one of two
different cylinders:

Lubricated An abbreviated term for oil-lubricated compressors, lubricated models

use oil to maintain the integrity of the cylinders, piston, and piston rings. The upside to
this design is that it usually requires little maintenance aside from having to periodically
service the filtration system.
Non-lubricated Using Teflon piston rings in place of oil, this variety requires no
lubrication and is often lighter in weight due to the use of aluminum components in
place of cast iron. Similar to the service requirements for lubricated models, the Teflon
rings have to be continuously replaced.

Positive displacement aids in the dispersal of heat, often leveraging water-encased cylinders to
avoid buildup. Reciprocating compressors also incorporate intercoolers between each stage as
well as after-coolers that act as a final filter on heat and moisture before discharging the
pressurized air. In terms of capacity, these are the short duty models of the group, capable of a
max of 50 hp and 12,000 CFM at 125 psig.

Rotary screw air compressors

The second type of positive displacement compressor, rotary screw air compressors are built
with two or more interlocking screws that draw the air into the system. As the outside air is
pulled through the system, its compressed at increasing degrees and discharged at the desired
psi. Similar to the reciprocating variety, rotary screw models are also split into two unique
types:

Flooded Flooded compressors pair oil with the air being pressurized as it moves
through the system and then filters it out before discharge, recycling it back to the
sump for continued use. Regular maintenance for this type of compressor includes
routine changes for oil, filters, and separator.
Oil-free This type is exactly similar to its flooded counterpart with one major
exception: oil is replaced with non-contacting carbon ring seals that eliminate the
possibility of oil entering the air stream within the compression compartment. The one

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 disadvantage to this type is that it tends to suffer from excessive heat build-up as it
does not have the capability of inlet throttling, a feature that often makes the flooded
version preferred.

Rotary screw air compressors have a far greater capacity than reciprocating models, offering
anywhere from 7.5 to 100 hp with displacements of up to 2,500 CFM at 125 psig.

Centrifugal air compressors

The odd one out, centrifugal compressors are the largest of the three and powered by electric
motors or steam turbines to produce outputs up to 500 hp and 15,000 CFM at 125 psig. Used
primarily within large industrial manufacturing processes, this massive amount of pressure is
generated through staged compressions, often requiring 2 to 5 stages.

Unlike the positive displacement type, centrifugal models contain at least two impeller
assemblies that rotate to compress incoming air. This rotation causes velocity, creating energy
thats used to pressurize the air. The upside to this design is that its capacity is highly
customizable, easily regulated by adjusting air inlet or outlet as well as the speed of velocity.

Centrifugal compressors are substantially more costly than the other two models. And the
upfront cost is only the beginning. They require constant maintenance and often need costly
repairs on individual parts resulting from high velocities and continuous use practices.

Other options
While all air compressors are represented by one of the three types mentioned above, they are
also available in different designs to suit needs related to portability, size, and weight. Among
the most common designs are:

Portable Designed for easy

transport from one job to the next,
portable air compressors are
lightweight and often come mounted
on carriages containing 2 to 4
wheels. The obvious advantage is the
ability to take it anywhere, powering
air tools in an endless range of work
environments without needing extra
long air hoses to stretch from a
stationary location or truck mounted
compressor. This type usually falls
within the reciprocating family and
therefore produces less power overall
when compared to larger models.
Stationary Designed for long-term projects, stationary air compressors provide
substantially more CFMs than their portable cousins. They also require special

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 installation considerations that often include extra hosing drilled through walls and
mounted above work areas. Higher end rotary screw compressors are commonly
among this variety.
Truck mounted Truck mounted compressors are similar to stationary models except
they can easily be taken from one jobsite to another without disassembly and
reassembly. Plus, larger models are capable of powering multiple air tools at once.
Somewhat more environmentally-friendly, electric options are common among
mounted compressors, enabling you to save on the cost of fuel during continuous use.
But, like a stationary model, youll have to run hoses from the truck to the work area
and account for a loss of air pressure that can range between .7 to 25 CFM depending
on the length of the run.
Towable Often found on construction jobsites or within forestry applications, towable
air compressors are mounted atop trailers featuring heavy duty steel chassis and fully
galvanized canopies. Often featuring a simple connection like a lifting eye hitch, they
can be hitched onto any large work vehicle and provide outputs from 14 to 327 hp and
50 to 1,200 CFM (at 125 psig).

Specs

There are a few key areas that can be used to compare both the value and usability of an air
compressor. So when comparing different models, heres what you should be on the lookout
for.

Stages
The term stages is used to describe the cylinders in an air compressor. You have two options:
single stage and multistage.

Single stage compressors are built with only one cylinder that compresses the air, often
capping out around 120 psi. This is usually adequate for home use or smaller shops that only
power one tool at a time. If youre looking for portability (and an air compressor that can easily
be carted and lifted), single stage is the way to go.

Multistage compressors are designed for multiple pneumatic air tools and those that require
more than 120 psi. With more than one cylinder, the air is first compressed in the initial cylinder
and then compressed in each successive cylinder to achieve higher levels of power. Due to the
additional mechanical processes involved, multistage compressors generate more heat and
require a cooling component, often in the form of a radiator.

Power
This may be decided for you if you plan on using the compressor in an enclosed area which
immediately disqualifies gas and diesel-powered compressors due to the exhaust they
produce. Output also often determines the power source, with diesel engines capable of
greater horsepower than electric models.

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In general, youll have a choice between these three options:

Gas Often portable, gas-powered compressors are a strong alternative in rural areas
and jobsites that arent connected to the power grid. Unfortunately, they can weigh in
excess of 200 pounds in some cases. Youll find two different types: those with an
electric generator that powers a cylinder and those that power the cylinder directly.
The downside to this setup is they tend to generate more noise than other models and
also require the storage and transport of additional fuel. But if you need a multi-stage
compressor, this will probably be one of your only options.
Diesel Diesel models usually provide the highest levels of output, commonly ranging
from 185 to 1,600 CFM far and above that of gasoline or electric compressors. This is
why diesel is often the power source behind truck mounted and towable models,
enabling them to provide higher torque and greater capacity for a wide range of air
tools connected simultaneously. Similar to their smaller gasoline counterparts, you are
required to keep extra fuel on hand. But diesel models are often engineered with
smaller tanks that allow them to be mounted efficiently on a variety of work vehicles.
Electric Reportedly one of the most common types of air compressor, as theyre
typically lighter and more compact, electric models are environmentally friendly and
can be used safely in enclosed spaces. Most are powered simply by plugging them into
a standard wall socket, though larger models that produce higher CFMs may require
access to higher voltage. Its worth noting that this type of compressor requires longer
air hoses as some experts discourage the use of extension cords with air compressors.

Purchasing tip: Make a list of every air tool that will require power simultaneously and plan
ahead. Under-buying will quickly burn out your compressor, regardless of its power source.
And over-buying can be just as bad. Youll be paying unnecessarily for surplus gas, diesel, or
electricity.

CFM, PSI, and horsepower

CFM or cubic-foot-per-minute is the measurement of delivery with respect to inlet. In short, it
gauges flow, not volume. PSI or pounds-per-square-inch is the pressure that results from one
pound-force directed at an area of one square inch. This results in a measurement of resistance
to flow.

Mathematics aside, when evaluating air compressors youll need to be aware of both the CFM
and PSI but one more than the other. Many air tools operate at 90 psi, with compressors
providing anywhere from 75 to 175 psi as a result.

CFM is more important. In fact, some experts cite it as one of the most important purchase
considerations when buying an air compressor. If you plan on powering more than one tool or
pneumatic device off of a single compressor, youll have to add up the CFMs for each to ensure
you have enough output to power them all. Youll also want to consider exceeding the total by
anywhere from 25% to 40% to allow for a buffer and prevent overworking the compressor.

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CFM requirements are usually listed on the packaging and can also be found on the
manufacturers website.

Finally, horsepower. According to a leading air compressor manufacturer, horsepower is

important but not nearly as important as CFM when comparing different compressors.
Larger air compressors often boast higher horsepower and lower CFMs. Unfortunately, these
models tend to run hotter and give out sooner than others. So when purchasing a new or used
air compressor, pay attention to the CFM rating first and all else second.

As a general reference, here are some popular tools and their average CFM requirements:

Pneumatic Air Tool CFM @ 90 PSI Pneumatic Air Tool CFM @ 90 PSI
Angle Disc Grinder (7") 6 CFM Grease/Caulking Gun 4 CFM
Air Drill (1/2" or 3/8") 4 CFM Hydraulic Riveter 4 CFM
Impact Wrench (1/2" or
Brad Nailer .3 CFM 2.5 - 7 CFM
3/4")
Chisel/Air Hammer 3 - 11 CFM Nailer 1 CFM
Drill 3 - 6 CFM Ratchet (1/4" or 3/8") 3 - 6 CFM
Dual Sander 6 - 11 CFM Spray Gun 6 - 18 CFM

Choosing a Quality Seller

As mentioned briefly in the introduction, a professional seller is an enormous benefit when it

comes to the selection process and post-sale support. Specializing in the specific brand and
application youre interested in, a professional air compressor seller provides additional
resources and information that can include the following.

Safety resources and laws

Though compliance isnt mandatory for air compressor operators, OSHA published a checklist
of safety suggestions for air compressors. Largely addressing issues related to service and
maintenance, a qualified seller can address each of these concerns and will often build them
into a service level agreement that routinely inspects each component for wear.

Warranties and service level agreements

Many quality air compressors are backed by a full warranty. But the specifics of those
warranties often vary from company to company. Others offer a selection of warranties that
cover popular parts for a set term: 3-year, 5-year, 7-year, and 10-year are common examples.
Items covered typically address issues related to:

Airends
Variable speed drives

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 Drive motors
Rings
Gaskets
Suction/discharge valves
Air/fluid receivers
Drive couplers
Coolers

Service level agreements (also known as SLAs) are above and beyond the warranty. They
outline a routine service plan designed around preventative maintenance. Offered for an
annual fee (or sometimes on a monthly basis), common items included in this type of post-sale
support include:

Oil levels
Belt tension
Coolers
Electrical connections
Air filters
Valves
Traps

Strength of manufacturer
Most air compressors are produced by companies with long-established histories Ingersoll
Rand, Campbell Hausfeld, Hitachi, Husky, Maxair, Sullair, and Kaeser to name just a few. These
brands have extensive dealer networks through the United States and around the world.

Nevertheless, check into the dealer in your local area. Is it a new business or have they been
around for awhile? A seller that's been offering the same air compressors for 10 or 15 years
obviously knows what theyre doing and has an established track record of quality service. This
also indicates they will more than likely be around for the foreseeable future to provide the
support necessary for your compressor.

Questions to ask
Whether youre buying a new or used air compressor, here are a few questions to ask the seller
to ensure you get the right machine for your intended use:

How long have you been in business?

What industries do you specialize in? And how many air compressors have you sold like
the one Im interested in?
With my application in mind, what are some of the common problems other buyers
have encountered with this compressor? What was the solution?
What type of warranty covers this air compressor?
What are your service hours? And how quick is your average response time?

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Free purchase comparison
Tracking down qualified sellers isnt easy unless you have us on your side! Take a moment to
fill out the quote request form youll find here and well connect you with a variety of
established air compressor sellers in your local area for free!

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About Purchasing.com
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